🏷️ Basic Information Identification Make: Hodaka Model: 90 / 125cc Series Product Type: Service Repair Manual Codes Applicable Years: 1964-1975 👋 Introduction Market Position Target Audience: Hodaka owners, vintage motorcycle enthusiasts, DIY mechanics, and off-road racers. Competitive Analysis Value Proposition: Provides essential information for maintaining and repairing a significant range of Hodaka models, saving on professional service costs and enabling performance tuning. Key Features Delivery Method: Instant Download Emphasis: Practicality and DIY focus 📋 Manual Details Coverage Areas Primary Coverage: Service, Repair, Maintenance, Troubleshooting, Competition Preparation Specific Systems Covered: Engine, Transmission, Clutch, Fuel System, Exhaust System, Electrical System, Wheels, Tires, Brakes, Steering, Suspension, Frame Page Count Estimated Page Count: Varies (Digital Manual - Printable Pages) Manual Type Type: Service Repair Manual Language Language: English Format File Format: PDF Compatibility: All Windows & Mac Versions Reader Requirement: Adobe PDF Reader 📖 Manual Coverage Systems Covered Engine Section: Engine disassembly, assembly, inspection, tuning, and troubleshooting for 90cc and 125cc variants. Transmission Clutch Section: Service and repair procedures for the gearbox and clutch mechanisms. Fuel Exhaust Section: Carburetor tuning, fuel tank, fuel lines, and exhaust system maintenance and repair. Electrical Section: Ignition system, lighting, wiring diagrams, charging system, and battery service. Wheels Tires Brakes Section: Wheel and tire service, brake system inspection and repair (drum brakes common). Steering Suspension Frame Section: Handlebar, front fork, rear suspension, swingarm, and frame inspection and repair. Procedures Included Maintenance Procedures: Periodic maintenance checks, lubrication points, filter changes, and adjustments. Troubleshooting Procedures: Diagnostic flowcharts and common problem identification and solutions. Repair Procedures: Step-by-step instructions for component removal, repair, and reassembly. Competition Prep: Guidance on preparing the motorcycles for off-road competition and racing. Technical Depth Depth Of Coverage: Comprehensive, covering basic to advanced repair and tuning tasks suitable for DIY enthusiasts and experienced mechanics. 📊 Manual Specifications File Format File Quality: High Quality Diagrams and Instructions Printability: All pages printable Searchability: Likely text-searchable PDF (depending on original scan quality) Binding Type Binding: N/A (Digital Download) Paper Type Paper Type: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Engine Type: 2-stroke, air-cooled, single-cylinder Bore Stroke 90Cc Typical: Approx. 49mm x 49.5mm Bore Stroke 125Cc Typical: Approx. 54mm x 54mm Reed Valve Induction: Common on many Hodaka models for improved performance. Performance Horsepower Range 90Cc: Approx. 7-10 HP Horsepower Range 125Cc: Approx. 10-15 HP Fuel System Carburetion: Typically single Mikuni or Keihin carburetors (e.g., VM26 for 125cc models). Fuel Type: Unleaded gasoline mixed with 2-stroke oil (specific ratio detailed in manual). 🔧 Transmission Standard Type: Constant mesh, sequential, foot-shifted manual transmission. Gear Count: Typically 5-speed. Features Clutch Type: Wet, multi-plate clutch, operated by cable and lever. Transmission Oil Type: Typically SAE 80 or 90 gear oil (specific grade in manual). 📐 Dimensions Exterior Classification: Lightweight dual-sport/off-road motorcycles. Weights Dry Weight Typical: Approx. 160-185 lbs (73-84 kg) 🛡️ Safety Features Ratings Safety Standards: Pre-dates modern standardized safety ratings; relies on rider skill and adherence to mechanical best practices. Active Features Braking System: Drum brakes front and rear (design varies by model and year). Passive Features Lighting: Headlight, taillight/brake light, turn signals (depending on homologation/market). 💡 Technology Features Infotainment Infotainment System: N/A (Basic motorcycle technology of the era) Driver Assistance Assistance Features: N/A Connectivity Connectivity Features: N/A 🔧 Maintenance Service Intervals Oil Change Transmission: Recommend every 3,000-5,000 miles or annually, per manual guidance. Spark Plug Replacement: Every 3,000-5,000 miles or as needed based on condition. Air Filter Cleaning: Frequent checks and cleaning/replacement, especially in dusty conditions, as detailed in the manual. Fluid Specifications 2 Stroke Oil Mix: Specific ratio (e.g., 20:1, 25:1, 32:1) will be detailed in the manual for different operating conditions. Fork Oil Type: Typically SAE 10W fork oil (specific quantity and type in manual). Known Issues Carburetor Tuning: Carburetors (Mikuni/Keihin) may require periodic cleaning and adjustment for optimal performance, especially with ethanol fuels. Clutch Wear: Clutch plates can wear over time and require replacement, as outlined in the manual's repair section. Electrical Connections: Older wiring may corrode; the manual's wiring diagrams are crucial for troubleshooting. Engine Seals: Crankshaft seals can degrade, leading to air leaks and poor running conditions. 📚 Vehicle History Brand Heritage Manufacturer Origin: Hodaka motorcycles were produced by the Hodaka Corporation in Japan, with significant distribution and sales in the United States by Pabatco. Model Evolution Model Lineup: The 90cc and 125cc models were core to Hodaka's success, known for their robust, simple, and competitive designs, particularly in observed trials and desert racing. Notable Models: Includes variations like the Super Rat, Combat Wombat, and Ace 90/100/125, which were highly popular in their era. Production Production Period: Hodaka production spanned from the mid-1960s to the early 1980s. This manual covers the key 90cc and 125cc models from 1964 through their evolution to 1975. 🏆 Awards & Recognition Recognitions Model Reputation: Hodaka models of this era were highly regarded...